1
Operating and
Maintenance Manual
DVH 600
0140202
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Table of contents
Introduction 4
Safety guidelines 5
Graphic presentation 8
Device description 9
Technical data 10
Activities prior to starting work 12
Starting 13
Driving and compacting 14
Shutting down 15
Maintenance overview 17
Maintenance work 19
Operating uids and ll levels 27
Troubleshooting 27
Storage 28
Hydraulic circuit diagram 29
4
Introduction
This operating and maintenance manual is designed to facilitate familiarization with your roller,
and to enable you to maintain the compactor and use it for its intended purpose.
When complying with the instructions in the operating and maintenance manual you help avoid
hazards, reduce repair and downtime costs, and increase the reliability and service life of your roller.
This operating and maintenance manual must always be available at the implementation site of
the roller.
If necessary you can obtain additional information from your authorized WEBER dealer, or you can
obtain information from one of the contact addresses on the last page.
The valid conformity declaration is enclosed with every machine delivery.
You can obtain information on the assembled Kohler diesel engine at www.kohlerpowerit.
5
Safety guidelines
General
All safety instructions must be read and complied with, non-compliance results in
– Danger to life and limb of the user
– Impairments to the machine or other property.
In addition to the operating manual, the accident-prevention regulations in the country where
the appliance is used must be complied with.
Intended use
The roller should only be used in technically faultless condition, as intended, in a safety-conscious
and hazard-conscious manner, in compliance with the instructions in the operating manual.
Malfunctions that impair safety must be eliminated without delay.
The DVH 600 roller is designed exclusively for compacting
– bituminous material (road surfaces); and
– light compaction tasks for earth works.
Any other use of the roller is considered to be non-intended use, for which the customer is
exclusively responsible. All liability is rejected if damage occurs due to non-compliance with
this provision. This risk is borne solely by the user.
Easily foreseeable misuse
Any use for which the machine is not intended.
Operation
Rollers are only permitted to be operated by suitable persons of at least 18 years of age. Operators
must be instructed in how to guide the roller by the owner or by owner’s assigned personnel.
The machine operator must comply with trafc regulations. If instructions that affect safety are given
by third parties, then the operator must be authorized to reject these instructions.
Protective equipment
This machine is capable of exceeding the permissible sound level of 80 dB(A). The owner might
also face additional dangers when using the machine. Precautionary action must, therefore,
be taken.
Unauthorized persons are forbidden from being in the area of the roller during the compacting
process.
Protective equipment includes:
Hearing protection
Hard hat
Safety shoes
Protective gloves
6
Operation under difcult conditions
Never inhale the exhaust gas; it contains carbon monoxide, a colorless and odorless gas that
is extremely hazardous, which, if inhaled even briey, can cause unconsciousness and death.
Therefore, never operate the engines in enclosed areas or in areas that are poorly ventilated
(tunnels, caves, etc.). Exercise particular caution when operating the engine in the vicinity of
people and livestock.
Operation
Prior to starting work the owner of the roller must be familiar with the working environment. The work
environment includes obstacles in the work and trafc area, the bearing capacity of the ground,
as well as the necessary safeguarding of the construction site in the area adjacent to public trafc;
and it includes compliance with trafc regulations.
The roller should only be operated when the protective xtures are mounted. The protective xtures
must all be in functional condition.
At least once per shift the roller must be checked for apparent defects. If there are apparent defects
then operation of the roller must be stopped immediately, and the responsible person must be
informed. Prior to restarting, roller malfunctions that have occurred must be corrected.
Always maintain adequate clearance to the edges of pits and embankments.
Do not drive on slopes in the transverse direction in order to prevent the roller from tipping over.
After work has been concluded secure the roller in accordance with statutory regulations, particularly
in the area of public trafc surfaces.
Maintenance and repair work
Only use original Weber spare parts to ensure reliable and safe operation for maintenance
or repair work.
Hydraulic hose lines must be checked at regular intervals in accordance with standard engineering
practice, or they must be replaced at appropriate intervals, even if no signs of safety-relevant defects
are present.
Adjusting tasks, maintenance tasks, and inspection tasks must be carried out on schedule as
specied in this operating and maintenance manual. These activities should only be executed
by instructed personnel.
For repair, maintenance, or inspection work the engine of the roller must be safeguarded against
unintentional starting.
All pressurized lines, particularly hydraulic lines and lines of the injection system of the drive motor
must be depressurized before performing maintenance or repair tasks.
For maintenance and repair tasks the roller must be placed on a level and stable substrate and must
be secured from rolling off or tipping over.
Heavy components and assemblies must be secured to and lifted by hoisting machines that can
bear their weight when they are replaced. Ensure that no hazard is caused by raising components
or assemblies.
Do not position yourself or work under suspended loads.
If lubricating oils and fuel come into contact with skin, they can cause skin cancer. Upon contact
with the skin, clean affected skin with suitable cleaning agent without delay.
7
Inspection
Rollers must be inspected in accordance with the corresponding implementation conditions and
operating conditions, as needed; however an inspection to ensure operationally safe status must be
performed by an expert at least once a year. The results of the inspection must be recorded in writing
and must be stored at least until the next inspection.
Cleaning work
Prior to cleaning the roller with a high-pressure cleaner, protect all accessible energized switches,
cable connections, etc. against water penetration by masking them off.
Cleaning tasks should only be executed in areas that are suitable and have been approved for
this purpose (oil separator amongst others).
Disposal
All operating uids and auxiliary materials must be disposed of in an environmentally-compatible
manner in accordance with country-specic regulations.
Warning against irritants or materials hazardous to health
Warning against a hazardous place
Warning against a suspended load
Wear ear protection
General regulation
Environmental protection
Important information for operating and maintenance personnel is marked by pictograms.
Hard hat
Safety shoes
Protective gloves
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425
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Graphic presentation
Overall view DVH 600
1 Manual guidance rod
2 Hydraulic tank
3 Lifting ring
4 Water tank
5 Fuel tank
6 Engine
7 Reversing starter
8 Hydraulic oil lter
(without illustration)
9 Scraper
10 Drums
11 Chain guard
12 Parking brake
13 Gas lever
14 Vibration lever
15 Safety bar and drive lever
16 Crush guard
17 Hearing protection (sticker)
9
Device description
The DVH 600 roller is used for compaction work in road building applications.
Drive
The compactor is powered by an air-cooled Kohler diesel engine.
Function
Start the Kohler diesel engine with the attached reversing starter.
The two drums are hydrostatically powered via chains. The chain drive is executed individually
on each bandage. The chain drive also serves as a safety braking system for operating on slopes.
The vibrator that is positioned outside between the two drums is powered via a V-belt.
The hydraulic system consists of a closed circuit with hydraulic pump and hydraulic motor as well
as a hydraulic tank.
The drums are freed of adhering material by the adjustable scrapers.
Operation
Use the gas lever to vary the engine speed between idle and full throttle.
The manual guidance rod is used to steer the roller. All control levers are located on the
manual guidance rod. Direction of travel and speed are controlled with the safety bar (drive bar).
The vibration adjustment lever switches vibration on or off. The arrest lever activates the parking
brake that stops the rear drum.
For safety of the operator a crush guard is attached to the manual guidance rod. If the operator
bumps against the crush guard when moving in reverse, the machine comes to a stop.
10
DVH 600
Weight
Dead weight (in kg) 400
Operating weight CECE in kg 420
Average stat. line load (in N/cm) 31.7
Dimensions
Overall length (in mm) 1885
Overall width (in mm) 755
Height (in mm) 1046
Drum width (in mm) 650
Drum diameter (in mm) 325
Axle base (in mm) 450
Lateral Overhang L/R (in mm) 15 / 90
Drive
Engine manufacturer Kohler
Type KD 15-350
Performance at operating speed in accordance with ISO 3046-1 (kW) 4,6
Combustion process 4-stroke diesel
Operating speed (m/min) 3000
Traversing mechanism hydrostatic Both drums
Movement speed (in km / hours)*
– Working motion forward / reverse 0 – 3.5 / 0 – 1.5
– Drive motion forward / reverse 0 – 3.5 / 0 – 1.5
Climbing capacity (in %)* 40 / 30
Operating brake Hydrostatic
Parking brake Mechanical
Brake effective at friction
µ = 0.25 (steel drum on rm
rocky ground) to 20 % ^= 11.3°
slope (longitudinal gradient)
Vibration
System Central exciter outside
of the drums
Drive concept Mechanical, connectable
Frequency (in Hz) 60
Amplitude (in mm) 0.34
Centrifugal force (in kN) 10
Technical data
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DVH 600
Noise emissions in accordance with 2000/14/EC
Sound pressure level LPA ascertained in accordance
with EN 500, in dB (A)
92
Sound power level LWA ascertained in accordance
with EN ISO 3744 and EN 500, in dB (A)
108
Vibration values
Root-mean-square acceleration value
for hand-arm vibration ascertained in accordance
with EN 500 in m/s²
3.7 / 6.1
In accordance with directive 2006/42/EC,
complying with the vibration values is the
owner’s responsibility.
1 Description 2 TYPE
.................................................... ....................................................
3 Serial number 4 Year of construction
.................................................... ....................................................
5 Mass 6 Rated power kW
.................................................... ....................................................
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Transport
Fit the crane hook into the lifting ring (1) and lift the machine
onto the desired means of transport.
Only use lifting machines with a minimum bearing
capacity of 500 kg.
Arrest the manual guidance rod (1) with the spring bolt (2).
Unscrew and remove the gas cap (1), check the ll level,
if necessary top off with clean diesel fuel to the lower edge
of the ller neck.
The correct oil level is between the min. and max. marks.
Checking the engine oil level
Pull the oil dip stick (1) out of the crankcase.
Check the fuel level
Activities prior to starting work
Do not step under suspended loads.
When transporting the soil compactor on a vehicle,
secure it with suitable restraints.
For work at the fuel system, have a suitable re-
extinguishing agent at the ready.
Fire, naked light, and smoking is forbidden!
min max
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Starting
Bring the gas lever (2) into full-throttle position.
Check the hydraulic oil level when the machine is at operating
temperature. The correct oil level is reached when the oil is in
the middle of the view glass.
Check the hydraulic oil level
Slowly tighten the handle (1) of the reversing starter (2) until
resistance is noticeable.
Allow the handle (1) to glide back into the initial position, and
then forcefully and completely pull it through with both hands.
Allow the engine to warm up for a few minutes.
If ambient temperatures are below minus 5 degrees
Celsius comply with the instructions in the operating
manual provided by the engine manufacturer.
No hydraulic oil is consumed during operation. If the oil
level drops, you must check the hydraulic system for leaks
To start, push the vibration lever (1) to the left into the off
position (
).
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3
Forward
= Press the drive bar forward
Reverse
=Pull the drive bar back / down
Standstill
= Allow the drive bar to slide into 0 position
Driving and compacting
Bring the gas lever (1) into full-throttle position.
Push the drive bar (1) into the desired direction of travel.
Push the parking brake lever (1) into vertical position
(disengage).
Open the water shut-off valve (1).
Move the vibration adjustment lever (2) as far as it will go
to position ( ).
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The roller will come to an immediate stop as soon as the
drive lever (1) is released.
Always move the vibration adjustment lever (2) to the
stop, otherwise increased abrasion occurs on the V-belt.
Only run machine within reach of the manual guidance rod.
At obstructions (walls, pits, etc.), ensure that no one can
be caught between the machine and the obstruction; or
ensure that the machine does not slip into the pit.
If the operator bumps against the crush guard (3) when
moving in reverse, the machine comes to a stop.
Through swinging out the drive lever (1) forward in the
direction of travel, the crush guard is again lifted up.
Shutting down
Bring the gas lever (2) into idle position.
Close the water cock (1).
Move vibration lever (1) to position ( ).
Pull the arrest lever all the way back (horizontal) until it
locks in place on slopes the roller must additionally be
secured against rolling off via wedges!
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During breaks – even if they are short – the machine
must be shut down.
Parked devices that represent an obstacle must be
safeguarded against through conspicuous measures.
Move stop lever (1) to the left until the engine comes
to a standstill.
17
Maintenance overview
Maintenance interval Maintenance point Maintenance activity
After the rst
50 operating hours
Hydraulic system – Change hydraulic oil lter
Engine – Change the engine oil
Every 8 operating hours /
daily
Air lter –Clean air lter insert, check for
damage, replace if necessary
Hydraulic system – Check threaded unions, hoses
for leaks, tighten threaded unions
or change hoses as needed
–Only perform work if
the hydraulic system
is depressurized!!
Engine – Checking the engine oil level
Every 150 operating hours /
every 6 months
Vibration shaft – Check V-belt for damage
Engine – Change oil lter and engine oil
–Change the fuel lter
Drive chains – Lubricate, retighten if necessary
Scraper – Visually inspect or readjust
Every 300 operating hours /
every year
Complete roller – Check all modules for visible
damage and wear
– Remove fouling, old grease
and rust
Hydraulic system – Change hydraulic oil lter
– Change hydraulic oil
Water tank +
sprinkling system
– Clean, remove lime scale
Drive – Check drive chains and drive
pinion for wear; retighten as
needed
18
The regulations of the engine manufacturer must be complied with in addition to the above main-
tenance overview!
Work must be carried out using regulation tools, and the operating and maintenance manual must
be complied with for all work.
All maintenance work: Select a collection vessel that is large enough to prevent oil from spilling onto
the ground. Dispose of waste oil in an environmentally friendly manner (regulation on waste oils).
Dispose of oils, greases, cloths soaked in oil, and replaced parts with oil on them in an environ-
mentally friendly manner.
If lubricating oils and fuel come into contact with skin, they can cause skin cancer. Upon contact
with the skin, clean affected skin with suitable cleaning agent without delay.
Repairs exceeding the scope of regular maintenance may only be performed by trained personnel
acting in accordance with our repair manual.
Damaged hydraulic lines, V-belts, drive pinion and drive chains of the drive system must be repaired
by trained personnel following the repair manual before the roller is put back into operation.
If accessible during maintenance, check the condition and stability of all screws.
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Change the oil lter
Change the engine oil
Open the screw cap (1) of the oil ller neck.
Screw the oil drain pipe onto the engine drain valve (1) and
drain off the oil.
After emptying completely, unscrew the oil drain pipe
from the drain valve and ll with oil in accordance with
the specication.
Remove the cover cap (1).
Drain engine oil.
Only drain engine oil when at operating temperature.
Danger of scalding due to hot oil.
Only drain engine oil when at operating temperature.
Maintenance work
Replace oil lter (1) with a new element.
After replacing the lter element, seal the lter enclosure
with the cover cap.
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Clean / change air lter cartridge
Unscrew the air lter cover (1).
Remove the air lter insert (1) from the air lter enclosure.
Clean air lter insert as specied by the engine manufacturer
if there is damage or if it is extremely dirty.
Change the fuel lter
Pull the fuel line (2) off the fuel lter (1) on both sides.
Replace the lter with a new lter element.
Dispose of oils, greases, cloths soaked in oil, and replaced
parts with oil on them in an environmentally friendly manner.
If lubricating oils and fuel come into contact with skin, they
can cause skin cancer. Upon contact with the skin, clean
affected skin with suitable cleaning agent without delay.
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